Prefabricated interlocking wall panel

ABSTRACT

A building panel construction consisting of inner and outer panel members secured together in spaced parallel relation in any convenient manner. Spacing studs are secured between and extend along, in recessed position, each pair of corresponding vertical edges of the panel members and define laterally outwardly opening channels extending along the vertical edge portions of each panel construction. A rib or tongue member is supported from and extends along each stud within the corresponding channel and each rib or nesting tongue is spaced from the inner surface of one panel member a distance substantially equal to the thickness of one of the panel members and the spacing between each nesting tongue and the other panel member is substantially equal to the thickness of the nesting tongue. In this manner, adjacent edge portions of adjacent panels may be laterally offset the thickness of one of the panel members thereof and advanced into position with the edge-defining components of the panel constructions secured together in interdigitated relation. The outer faces of the ribs or nesting tongues are provided with stiff but flexible membranes of somewhat greater width than the nesting membranes themselves and accordingly, these membranes define tight edge-tosurface engaged weather-tight and vapor seal joints between joined marginal edge portions of adjacent panel constructions.

[4 June 18, 1974 PREFABRICATED INTERLOCKING WALL PANEL [75] Inventor:Gehres D. Weed, Edmonton,

Canada [73] Assignee: Frank Stackaruk, Edmonton,

Alberta, Canada; a part interest [22] Filed: Jan. 18, 1973 [21] Appl.No.: 324,799

[52] US. Cl 52/238, 52/519, 52/588,

52/593 [5]] Int. Cl E04!) 2/74 [58] Field of Search 52/588, 569-572,

Primary Examiner-Frank L. Abibott Assistant Examiner-Carl D. FriedmanAttorney, Agent, or Firm-Clarence A. OBrien; Harvey B. Jacobson 7]ABSTRACT A building panel construction consisting of inner and outerpanel members secured together in spaced parallel relation in anyconvenient manner. Spacing studs are secured between and extend along,in recessed position, each pair of corresponding vertical edges of thepanel members and define laterally outwardly opening channels extendingalong the vertical edge portions of each panel construction. A rib ortongue member is supported from and extends along each stud within thecorresponding channel and each rib or nesting tongue is spaced from theinner surface of one panel member a distance substantially equal to thethickness [56] References Cited of one of the panel members and thespacing between UNITED STATES PATENTS each nesting tongue and the otherpanel member is l 083 697 14 Neptune 52/753 B substantially equal to thethickness of the nesting 2 332 732 10/1943 Laucksm 52/617 tonguemanneradlacem edgfi e of adla' 2:381:635 8/1945 Baker 52/408 Cent Panels maybe laterally Offset the thlckness 0f One 2,706,838 4/1955 Sears 52/593Ofthe Panel members thereof and advanced into P 2,872,882 2/1949 Paul52/408 lion with the g g Components Of the Panel 3,077,703 2/1963Bergstrom 52/595 constructions secured together in interdigitatedrelatlOl'l- Th outer faces Of the ribs 01' nesting tongues are providedwith stiff but flexible membranes of some- 1 3555;? 3:32? 22:52? 52 whatgreater width than the nesting membranes themselves andaccordingly,these membranes define tight edge-to-surface engaged weather-tight andvapor seal joints between joined marginal edge portions of adjacentpanel constructions. I

5 Claims, 4 Drawing Figures 1 i I 1 I l .l 5

This invention relates to a prefabricated wall structure and morespecifically to a prefabricated sectional wall panel which may beemployed for either pennanent or temporary use.

Prefabricated sectional wall panels are well known and widely used.However, these panels are usually very complicated in structure and aredifficult to erect. Also, the component parts of conventionalprefabricated panels usually require cutting and finishing at the actualbuilding site and, due to the non-uniformities in buildings, thefinished component parts are not reusable when re-located. Therefore,prior art prefabricated wall panels are problematical to erect, and themethod of erection is expensive and time-consuming.

As a result, there have been attempts to provide prefabricated wallpanels with built-in edge structures such that a wall can beconveniently erected by engagingadjacent panels together at the buildingsite without cutting and finishing. This has been achieved by providingcomplementary vertical edge structures on each side of the panel, forexample, a tongue portion on one vertical side edge and a complementarygroove on the other side edge. Erection of this type of panel issimplified by merely matching the tongue of one panel with the groove ofthe adjacent panel. However, this type of construction is notsatisfactory inasmuch as at least two different types of vertical edgesmust be incorporated on each panel. The cost of manufacturing isincreased and mass manufacturing is difficult. Furthermore, the jointsformed by this type of panel are not air-tight and they are particularlyunsatisfactory for use in constructing exterior wall structures.

It is therefore a principal object of the present invention to provide anovel wall panel which has a standardized edge structure utilized onboth edges of each panel.

It is another object of the present invention to provide a wall panelconstruction which will provide a weather-tight and vapor seal jointbetween adjacent panels.

It is still another object of the present invention to providecompletely finished panel component parts that require no cutting andfinishing at the actual building site. 1

Another object of the present invention is to provide wall panels thatcan be re-located at a new building site with 100 percent salvageabilitywithout loss of material and which are also capable of being taken apartat will for the purpose of re-location.

Briefly, the prefabricated wall panel of the present invention comprisesa standardized edge structure on each vertical side edge, which edgestructure includes an elongated nesting member or tongue provided withina lateral channel, the channel and elongated nesting member or tongueextending the entire length of each vertical side edge of the panel anda deformable semi-rigid membrane is disposed on and extends along eachnesting member, whereby the edge juncture between adjacent panels isinterlockable to form a weather-tight, vapor seal joint.

More particularly, the wall panel of the present invention comprises twoplanar boards disposed coterminously in spaced relation with apredetermined width therebetween. A stud member is secured and extendsalong between corresponding vertical edge portions of the boards spacedinwardly from the free edge portions thereof to form an outwardlyopening channel along each vertical side edge of the panel and elongatednesting members or tongues are secured on the outer side of each studmember within the corresponding channel with each nesting member ortongue spaced from the corresponding boards. The first channel segmenton one side of the nesting member or tongue and the corresponding panelboard is substantially equal to the thickness of the planar boards andthe second channel segment on the other side of the nesting member andthe other panel board is substantially equal to the width of the nestingmember strip or tongue. The semi-rigid membranes disposed on the nestingmembers are of such dimensions so that two adjacent panels areinterlockable along their vertical edges by engaging the nesting membersor tongues of one panel within the second groove segment of the otherpanel with the semi-rigid membranes flexed into position within thecorresponding channel segments to create firm edge pressure and form aweather-tight, vapor seal joint.

A final object of this invention to be specifically enumerated herein isto provide a prefabricated interlocking wall panel structure which willconform to conventional forms of manufacture, be of simple constructionand easy to use so as to provide a device that will be cconomicallyfeasible, long lasting and relatively trouble free in operation.

These together with other objects and advantages which will becomesubsequently apparent reside in the details of construction andoperation as more fully hereinafter described and claimed, referencebeing had to the accompanying drawings, forming a part hereof, whereinlike numerals refer to like parts throughout.

FIG. I is a perspective view of a portion of a wall structure erected inaccordance with the tion;

FIG. 2 is a plan view of the assemblage illustrated in FIG. 1;

FIG. 3 is a horizontal exploded sectional view illustrating therelationship of the components of two adjacent wall panel structuresimmediately before the wall panel structures being joined together; and

FIG. 4 is an enlarged fragmentary plan view illustrating a completedseal joint between adjacent panels of the present invention.

Referring now more specifically to the drawings, FIG. 1 illustrates ageneral perspective of an installed wall or partition 9 in accordancewith the present invention. In the particular structure: illustrated,which it will be understood is only by way of example, the wallcomprises prefabricated panels such as panels 10, 11 and 12. Thesepanels form a staggered relationship, namely, adjacent panels are joinedin an alternate offset manner. As shown in FIG. 1 and in FIG. 2, panel11 is offset from panels 10 and 12. Only three panels are shown forsimplicity, it being understood that a plurality of panels may be joinedin this alternate offset manner according to the present invention.

As shown in the exploded sectional plan view in FIG. 3, the panels 10and 11 comprise two pairs of coterminous planar boards l3, l4 and l5, 16held together in a conventional manner to form the prefabricated panel.Elongated stud members 17 and 18 are secured between the vertical edgesof the planar boards forming channels within the edge portions of theboards. The

present invenedge portions of the boards form flanges 19, 20 and 21, 22respectively, for the channels. The channels are of predetermined widthwhich will be apparent from the following description.

Nesting strips, splines or tongues 23 and 24 have a substantiallyrectangular cross section and are received within the channels in amanner in which one pair of sides 25 and 32 of the nesting strips 23 and24 are spaced from the flanges l9 and 22 respectively and define spacesor channel segments 26 and 30 of a width substantially equal to thethickness of the planar boards 21 and 20. The spaces 28 and 29 betweenthe nesting strips 23 and 24 and channel flanges 20 and 21 aresubstantially equal to, or slightly greater than, the width of thenesting strips. Each nesting strip extends the entire length of thevertical edges of the panels. Additionally, semi-rigid membranes 33 and34 are provided on the outer surfaces of the nesting strips 23 and 24 asshown. The semi-rigid membranes may be one of many materials such aspaper, plastic, metal, etc. adhered, or otherwise secured, on theoutermost edges of the nesting strips or tongues.

It is apparent that the edge structure of the panels and 11 as shown isthe reverse of each other. That is, panel 10 has an identical edgestructure on both vertical edges, while panel 11 is merely a similarpanel turned upside down and inside out or simply turned about insideout to obtain a matching edge with the adjacent panel 10.

in use, flange 21 and nesting strip 24 of panel 11 are received withinspaces 26 and 28, respectively, of panel 10 and flange and nesting strip23 of panel 10 are received within spaces 30 and 29, respectively, ofpanel 11. The semi-rigid membranes serve the purpose of providing aminimum of friction in joining the panels together and are deformedunder force to provide a maximum of edge pressure on the flanges of thechannel and on the nesting strips or tongues thus forming aweather-tight, vapor seal joint.

The panel according to the present invention is most suitable for use asan exterior wall structure in which a vapor seal joint is particularlyessential for preventing vapor from passing in or out of the building.It may also be conveniently used to construct interior partition wallsin which the seal joint also provides a good acoustical insulation. Thesystem can be applied to joining floor or roof panel vapor seals andspace may be afforded for deformation of the flexible semi-rigidmembrane.

in order to facilitate joining between the panels, the front corners ofthe nesting strips or tongues are beveled such as shown by 35, 36 and37, 38 of nesting strips or tongues 23 and 24, respectively, in FIGS. 3and 4. it is obvious that although the nesting strip shown has asubstantially rectangular cross section, it may be in other forms suchas having a wedge, half oval or rhombus cross section.

The exposed surfaces of the nesting strips and the semi-rigid membranesare preferably located below the top of the flanges of the channels sothat they are protected from damage in handling.

The foregoing is considered as illustrative only of the principles ofthe invention. Further, since numerous modifications and changes willreadily occur to those skilled in the art, it is not desired to limitthe invention to the exact construction and operation shown anddescribed, and accordingly all suitable modifications and equivalentsmay be resorted to, falling within the scope of the invention.

What is claimed as new is as follows:

I. A prefabricated wall panel comprising two planar boards disposedcoterminously in spaced relation with a predetermined width of spacebetween them, a stud member received within said space and disposed ashort distance from the vertical side edge of said boards to form achannel along said vertical side edge, elongated nesting means providedon said stud member within said channel wherein one vertical edge ofsaid nesting means being spaced from said one side wall of said channelforming a first groove within said channel substantially equal to thethickness of said planar boards, a second vertical edge of said nestingmeans being spaced from the other side wall of said channel forming asecond groove within said channel substantially equal to the width ofsaid nesting strip and a deformable semi-rigid but flexible membranedisposed on said nesting strip so that two adjacent panels areinterlockingly engageable along the vertical edges by engaging thenesting means of one panel within said second groove of the other paneland deforming said semi-rigid membrane within said channel to form aweather-tight vapor seal joint.

2. A prefabricated wall panel according to claim 1 in which said nestingmeans has a substantially rectangular cross section.

3. A prefabricated wall panel according to claim 1 wherein said nestingmeans includes beveled corners to facilitate interlocking betweenadjacent panels.

4. A prefabricated wall panel according to claim 3 in which said nestingmeans is disposed within said channel to prevent damage to said nestingmeans and said semi-rigid membrane during handling.

5. A panel construction including spaced first and second parallel panelmembers stationarily braced relative to each other, said panelconstruction including opposite generally parallel marginal portionsdefined by pairs of corresponding edge portions of said panel members,partition means secured between said edge portions inwardly of the freeedges thereof defining a pair of oppositely outwardly opening channelsbetween and extending along said edge portions, an elongated splinemember supported from each partition means disposed in and extendingalong the corresponding channel and spaced between said panel members,the spacing between said splines and one of said panel members being atleast equal to the thickness of the edge portions of the other panelmember and the spacing between said splines and the other panel memberbeing at least equal to the thickness of said splines, said splinesincluding stiff but flexible transverse membranes carried on their outerportions and projecting at least slightly outwardly of the oppositesides of said splines for deforming and flexure into tight membraneedge-to-spline and panel surface contact upon edge-toedge opposingfront-to-rear reversed panel constructions having their opposingmarginal portions interdigitated in slightly laterally offset relation.

1. A prefabricated wall panel comprising two planar boards disposedcoterminously in spaced relation with a predetermined width of spacebetween them, a stud member received within said space and disposed ashort distance from the vertical side edge of said boards to form achannel along said vertical side edge, elongated nesting means providedon said stud member within said channel wherein one vertical edge ofsaid nesting means being spaced from said one side wall of said channelforming a first groove within said channel substantially equal to thethickness of said planar boards, a second vertical edge of said nestingmeans being spaced from the other side wall of said channel forming asecond groove within said channel substantially equal to the width ofsaid nesting strip and a deformable semi-rigid but flexible membranedisposed on said nesting strip so that two adjacent panels areinterlockingly engageable along the vertical edges by engaging thenesting means of one panel within said second groove of the other paneland deforming said semi-rigid membrane within said channel to form aweather-tight vapor seal joint.
 2. A prefabricated wall panel accordingto claim 1 in which said nesting means has a substantially rectangularcross section.
 3. A prefabricated wall panel according to claim 1wherein said nesting means includes beveled corners to facilitateinterlocking between adjacent panels.
 4. A prefabricated wall panelaccording to claim 3 in which said nesting means is disposed within saidchannel to prevent damage to said nesting means and said semi-rigidmembrane during handling.
 5. A panel construction including spaced firstand second parallel panel members stationarily braced relative to eachother, said panel construction including opposite generally parallelmarginal portions defined by pairs of corresponding edge portions ofsaid panel members, partition means secured between said edge portionsinwardly of the free edges thereof defining a pair of oppositelyoutwardly opening channels between and extending along said edgeportions, an elongated spline member supported from each partition meansdisposed in and extending along the corresponding channel and spacedbetween said panel members, the spacing between said splines and one ofsaid panel members being at least equal to the thickness of the edgeportions of the other panel member and the spacing between said splinesand the other panel member being at least equal to the thickness of saidsplines, said splines including stiff but flexible transverse membranescarried on their outer portions and projecting at least slightlyoutwardly of the opposite sides of said splines for deforming andflexure into tight membrane edge-to-spline and panel surface contactupon edge-to-edge opposing front-to-rear reversed panel constructionshaving their opposing marginal portions interdigitated in slightlylaterally offset relation.